Not much comes out when you pull the CAD. Just jack up that side of the axle, and it will all run to the other side.

 

ok thanks, ill open it up thursday and if the spring is seated ill buy the seal install kit, large and samll bushings, u joint, and wheel bearing assembly, as well as inspect the sealing surface and splines and let you guys know the results.

could a bad u joint cause a leak? also does the driver side have bushings on the shaft?

 

also, how are the two bushings installed?

 

the larger inner bushing is installed into the tube, on the drivers end of the cad.
you can check it by wiggling the inner axle.
if it moves around excessively, not sure how much - say more than 1/16th of an inch, its worn out..
to remove it, you knock it, or pull it, into the cad cavity.
to remove it, you must first remove the passenger side brakes, bearing, outer axle, passenger side seal, collar. then remove passenger inner axle. if you're replacing drivers side seal, then also remove drivers side brakes, bearing, axle, differential.
knock out the large bushing from whichever side you have access.
i tapped mine out from drivers side using long pipe.
you could remove it from passenger side with slide hammer.

clean the inside of the axle tube to spotless condition. sheriff built a scraping tool. i used 90* hook bent into a pole. and about 4 cans of brake cleaner. and some gas, and a wire brush. it was bad...

reinstall new large bushing or bearing from the cad opening, using a large socket, approx 21mm.

take both axle halves and collar to the workbench.
remove small bushing from the end of the axle. break it out with screwdriver or punch as required. install new small bushing by tapping it into the end of the axle.
place the axle ends together like they will be installed in the truck.
check fit of how the collar slides back and forth over the inner axle, cad side splines. file off any burrs on either axle, or the collar, to make it smooth as silk.

install inner axle. grease the large bushing or bearing.

install passenger side seal. seat it all the way in. don't screw it up.
install collar onto inner axle. angled edge towards outside.

install passenger side axle into the tube. grease the seal and axle end, and lift the axle end through the seal from cad side to avoid any damage to the seal.
test everything - alignment of the axle halves. smoothness of collar slide. tight fit/no play between axle ends and all bushings.
bolt bearing into knuckle. install axle nut. torque everything.
install cad. verify shift fork straddles the collar.
with truck front end still on jack stands, crank it up and shift to 4wd. verify axle lock. shift to2wd. verify axle unlock, both by the 4wd light, as well as by turning passenger wheel and verify that drive shaft tries to turn or that drivers side wheel turns (4wd) or not (2wd). passenger side should freewheel in 2wd.

reassemble everything. top off the diff. you're done.

 

thanks for the write up man, does the inner shaft just slide out of the diff? will it be difficlult to get that bushing out from the passengers side? im not up for removing the carrier and punching it out from the drivers side

 

It just slides out when the axle shaft is out and the cad unit is off.

 

After the intermediate shaft is removed, the bearing should almost come out by using your finger. If not, just bend an old screwdriver and pull it out from one side to another in rotation.

Sorry, I should read previous posts better! What Sheriff said. I thought he was talking about the shaft itself.

 

You had it right the first time, I was talking about the intermediate shaft just sliding out of the differential.

 

Well thats ok, neither one of us can hold a candle to DV's post I can't "splain" things all that good. LOL I'd rather just do it.

 

sheriff is correct, once the outer axle is removed, then the inner axle just slides out. no c-clip nor retainer, nor anything.

large bushing or bearing should come out reasonably easy. like zman said, either finger, or 90* screwdriver, or worst case - slide hammer.

diff removal is only required for drivers side seal. stupid d44.
diff removal is not that bad. i used sheriff's trick of pulling with a come-along.

this will make a lot more sense when its all laid out in front of you.
just be sure you install the inner axle first and then the seal, because the seal is smaller than the inner axle. don't get out of order and put in the seal first, or your screwed.